Mounting concerns about the environmental and health effects of fluorine compounds are causing companies to rethink their use of these substances and to search for satisfactory replacements. MItsui Chemicals Europe is now touting its Mipelon, a spherical UHMW-PE fine powder, as a replacement option for PTFE.
According to the company, Mipelon provides benefits equal to or exceeding PTFE, in terms of sliding properties, abrasion resistance, and chemical durability in plastics, rubbers, paints, and coatings.
The main limitation in replacing PTFE with UHMW-PE is the latter's lower melting temperature of around 135°C. Mipelon can be used up to 120°C, while the speciality PM200C grade is suitable as an additive for hydrocarbon oils at temperatures up to 200°C. Unlike traditional PE powders, Mipelon does not swell at high temperatures, maintaining its shape and performance. Additionally, it has improved dispersibility in plastic masterbatches.
Mipelon often delivers a lower coefficient of sliding friction and enhanced abrasion resistance compared to PTFE, making it a cost-effective option. With a density of 0.97 g/cm³—about half that of PTFE—it also contributes to weight reduction. Mipelon is sold directly by Mitsui Chemicals Europe and through distributor Dreyplas, which offers customer support for new developments.
The molecular weight of Mipelon is approximately 2 million g/mol, and it features small spherical particles with a D50 average size of about 10 µm for PM-200, the smallest in its category. The XM-220 type has a D50 of 30 µm, while XM-330's is 65 µm. Coarser grades are used to modify rubbers and plastics, while finer grades are suited for paints and coatings. Mitsui Chemicals is also developing powder grades with D50 values under 5 µm, with samples of a 6 µm grade already available and commercial release expected by late 2025.
Mipelon's spherical particles have a smooth surface and a narrow size distribution, enabling excellent dispersion. Compared to PTFE, it has fewer coarse particles, lower friction coefficients, and better abrasion resistance under long-term stress, also outperforming PA11, PA12, and PE waxes.
It shows high chemical resistance to acids, bases, and organic solvents while absorbing minimal moisture. Many Mipelon types meet EU and US food contact regulations.
Typical applications include various coatings (electrostatic powder coatings, spray coatings, and dip coatings), rubber modification, and thermoplastics. Specific examples include rubber-coated rollers, automotive rubber profiles, polymer compounds, anti-blocking films, and emergency lubrication oils and greases.
Mitsui Chemicals and Dreyplas are collaborating with customers to replace PTFE with UHMW-PE and improve tribological properties, including the use of Lubmer UHMW-PE for extrusion and injection moulding applications.
Mitsui Chemicals Europe GmbH is the European arm of the globally operating Mitsui Chemicals Group, a Japanese producer and supplier of speciality chemicals and plastics.